1987-2006 Suzuki Lt80 (Lt-80) ATV Repair Manual

FOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance Bnd repair of the L Teo. The L T80 is a new type of vehicle that has many technical features such as: • V-belt drive automatic transmission • Forced air-cooling system • P. E. Ignition system • Electric starter system * Starter in terlock mechanism This mamual contains up-fa-date information at the time of its issue. Latermade modifica- tion and changes wilt be explained to each SUZUKI distributor in respective markets, to whom you are kindly requested to make query about up dated information, if any. The L T80 vehicles distributed in your country might differ in minor respects from the standard-specification and, if they do, it ;s because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country.

GROUP INDEX GENERAL INFORMATION ENGINE SERVICING FUEL AND LUBRICATION SYSTEM ELECTRICAL SYSTEM CHASSIS SERVICING INFORMATION LT80J f88-MODEL) LT80K f89-MODEL) L-_ LT _ 8 _ 0 _ L _ (_ '9_ 0- _ M _ O _ D _ E _ ~ ______________ ~ 1D2I L T80M/N/P/R/S/T IV /W /X/Y /K1/K2/K3 (1991 to

VIEW OF SUZUKI LT80 LEFT SIDE RIGHT SIDE I 1 •

GENERAL INFORMATION ,---------------CONTENTS ----------------, VIN AND SERIAL NUMBER LOCATIONS·· .. ··· ·.. ············· ·· .. ····· 1- 1 SPECIFICATIONS ···· ·· ······ .. .. .. ..... .. ........ .. .......................... · 1- 2 FUEL AND OIL RECOMMENDATIONS·· .. ···· .. ·········· .. ········· ·· .. 1- 4 BREJIII'/II!Ci-IN PROCEDURE························ ·· · ·· ····· ·············· · 1- 4 PRECAUTIONS AND GENERAL INSTRUCTIONS ··········· ·· · ·· ··· · 1- 5 SPECIAL MATERIALS ··········· ·· ················ ··············· .. ······ ··· ·1- 6 SPECIAL FEATURES ···················· ·· .. ················· .. · .. ·· ·· ······· ·1- 8 POWER TRANSMISSION ········· ·· ··········· ······ .. ·· .. ·· ···· ···· ·1- 8 FORCED AIR-COOUNG SySTEM ·············· ·· ··· ·· .. · ·· ······· ·1- 11

I-I GENERAL INFORMATION VIN AND SERIAL NUMBER LOCATIONS FRAME NUMBER The frame number or V I N (Vehicle Identification Number) is stamped on the front frame, left side. This number is required especially for registering the vehicle and ordering spare parts. ENGINE NUMBER The engine serial number is stamped on the up- side of the crankcase. This number is required especially for registering the vehicle and ordering spare parts. ,

SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length . . ....... . .......... , .... . . . Overall width . .......................... . Overall height . .... • .... •. . .... • ....... . .. Wheelbase . .. .. ..... . . , . ................ . Front track . .. .. ....... • ..... • . ...... • ... Rear track .......... ... ••.. . ••.. ... .•... Ground clearance . ....... • . ... . • ...... •... Seat height .. ... ...................... . . . Dry mass .. .. , .. . ... . .. ... ...... . .. . ... . ENGINE 1 430 mm 156.3 in) 800 mm 131 .5 in) 870 mm 134 .3 in) 940 mm 137 .0 in) 575 mm 122 .6 in) 630 mm 124 .8 in) 110 mm I 4.3 in) 645 mm 125.4 in) 99.5 kg 1219 lb.) G ENE R AL INFORMATION 1·2 Type . . ...... . ............... . .... , ..... Two-strok e, forced air·cooled Intake system . .. ....... . • ..... • ........ .. Reed val ve Number of cylinders . ..... . .... _ . . . . . . . . . .. 1 Bore . . ... .......... . .. .. .. ........ . .... 50 mm (1.969 in) Stroke . _ .. .. .. . .. ... .. ... . .. . ..... .. .. . 42 mm (1.654 in) Piston displacement ...... ... .............. 82.5 cm J (5.03 cu . in) Corrected compression ratio . ..... . .......... 7.4 : 1 Carburetor .. .. ...... . ........ .. .. .. . .... MIKUN I V M16SH. Single Air cleaner .. .. .. ................... . .... Polyurethane foam element Starter system ......... •• ............. . .. Electric Lubrication .ystem ........................ SUZUKI " CCI " TRANSMISSION Clutch ...... . ................ _ . . . . • . . .. Dry sh oe. automatic, centrifugal type Gearshifting ......... . ........ . ..... . .... Automat ic, variable ratio Gear ratios, variable ......... . .. •.. .. .. .... 2. 341 - 0. 852 Reduction ratio Gear • ..... . ........... ••. . . . 7.197 13311 2 x 2 71 14 x 19/ 14) Chain .... . .• ••. •• . •...•• .... 2.166 (26 / 12) Drive system . . .. .. ... ... .. ... ... ......... V-belt drive and chain drive Drive chain . ... . ........ . .. ' ..••.••.•. . .. DAIDO 0.1.0. 428 or TAKASAGO RK428 , 44 links

1·3 GENE RAL INFORMATIO N CHASSIS Front suspension ..... ... .. .. .. •.. ... . .... Strut type independent suspension Rear suspension ............. ••. .. . .. . ... . Unit- swing suspension Steering angle . ............ , • • ....... • .. ,. Inside 35°, Outside 27 ° 30' Caster . . . . . . . . . . . . • . . . . . . . . . • . . . . . . . . . .. 3° Trail . .... . ............. .. .. •.. •. ... .... 11.6 mm (O.46 in) Turning radius .. .................... . .... 2.3 m (7. 55 ftl Front brake ............... .• ...... .• .... Internal expanding Rear brake . ...... • ........ • • ............ Internal expanding Front tire size .. .... ... ....... .. .... .. .... AT 19 x 7.00- 8. (x2) Rear tire size ...... . .... . .. . ............. AT 19 x 7.00·8. (x2) ELECTRICAL Ignition type . . ..... ••••••••• •• . .... • . ... SUZUKI"PEI"' (COil Ignition timing .. ........... •• .... ..• • .... 22 0 B.T.D. C. at 4 000 rl min Spark plug ............ .. ... .. . .... . ..... NGK BPR7HS or NIPPON DENSO W22FPR ..... For Canada model NGK BP7HS or NIPPON DENSO W22FP·U ..... For the other models Battery ......... .... •..• ................ 12V 14.4kC (4 Ah )/ IOHR Generator . .... ... .. ... •. . .. ..• •.. . ..... . Flywheel magneto Fuse . .... , ......... • • .. ... . ..•• .. ... . . . 5A CAPACITIES Fuel tank including reserve .. .. . ..... . ....... 6.0 L (1.5811 .32 US/ Imp gal) reserve . ............ ..... 2.0 L (0.53/0.44 US/ Imp gal) Engine oil tank ............ . ......... . .... 1.2 L (1.27 1 1.06 US/ Imp qtl Final gear oil .......... . • ..... .•... ...... eo ml (2.70/2.82 US/ Imp oll * These specifications are subject to change without notice.

FUEL AND OILRECOMMENDA T IONS Be sure to use the specified fuel and oils. The fol - lowings are the specifications. FUEL Use only unleaded or low-lead type gasoline of at least 85-95 pump octane (R;M method) or 89 octa ne or higher rated by the Research Method. For other mode ls Gasol ine used should be graded 85 - 95 octane or higher. An unleaded or low-lead gasoline type is recommended . ENGINE OIL For the SUZUKI eel system, use of SUZUKI eel or eel SUPER Oil is highly recommended, but if they are not available, a good Quality two- stroke oil (non-diluent type) should be used . FINAL GEAR OIL Use a good quality SAE 20W/ 40 multi-grade motor oil. BREAKING- IN PROCEDURE During manufacture only the best possible materials are used and aU machined parts are finished to a very high standard but it is still necessary to allow t he moving parts to "BREAK-IN" before subject- ing the engine to maximum stresses. The future performance and reliability of the engine depends on the care and restraint exercised during its early life. The general rules are as follows: • Keep to these breaking-in speed limit : Up to 10 hours Less than 112 throttle • Upon passi ng 10 hours you can subject the moto rcycle to f ull thrott le operation. • Do not maintain constant engine speed for an extended time period during any portion of the break·in. Try to vary the throttle position. GENERAL INFORMATION 1-4

1·5 GENERAL INFORMATION PREAUTIONS AND GENERAL INSTRUCTIONS QbselVe the following items without fail when disassembling and reassembling ATV's. c Do not run engine indoors with linle or no ventilation. o Be sure to replace packings, gaskets, circlips, O-rings and cotter pins with new ones. CAUTION : Never reuse a circlip, After a circlip has been removed from a shaft, if should be discarded and a new circlip must be installed. When installing 8 new circlip. care must be taken not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip. always insure that it is completely seated in iu groove and securely fitted. o Tighten cylinder head and case bolts and nuts beginning with larger diameter and ending with smaller diameter, and from inside to outside diagonally, to the specified tightening torque. o Use special tools where specified. o Use genuine parts and recommended oils. o When 2 or more persons work together, pay attention to the safety of each other. o After the reassembly, check parts for tightness and operation. o Treat gasoline, which is extremely flammable and highly explosive, with greatest care. Never use gasoline as cleaning solvent. Warning, Caution and Note are included in this manual occasionally, describing the following contents. WARNING ................. . The personal safety of the rider or bystanders may be involved. Disregarding this information could result in personal injury . CAUTION . ... ............. .. These instructions point out special service procedures or precautions that must be followed to avoid damaging the machine. NOTE . ........................ This provides special information to make maintenance easier or important instructions clearer. REPLACEMENT PARTS When you replace any parts, use only genuine SUZUKI replacement parts, or their equivalent . Genuine SUZUKI parts are high quality parts whic" are designd and built specifically for SUZU- KI vehicles. CAUTION : Use of rep/acement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage.

1987-2006 Suzuki Lt80 (Lt-80) ATV Repair Manual

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